STILL STED Forklift Electric trucks Facelift 2014, including lithium-ion technology RX20-14 RX20-15 RX20-16 RX20-18 RX20-20 Workshop Manual – PDF DOWNLOAD

STILL STED Forklift Electric trucks Facelift 2014, including lithium-ion technology RX20-14 RX20-15 RX20-16 RX20-18 RX20-20 Workshop Manual – PDF DOWNLOAD

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STILL STED Forklift Electric trucks Facelift 2014, including lithium-ion technology RX20-14 RX20-15 RX20-16 RX20-18 RX20-20 Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 416
Downloadable : Yes
File Type : PDF

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STILL STED Forklift Electric trucks Facelift 2014  including lithium-ion technology RX20-14 RX20-15 RX20-16 RX20-18 RX20-20 Workshop Manual – PDF DOWNLOAD

DOCUMENTATION

This workshop manual contains all the information required to assist a competent person with all work, repairs and maintenance on this truck. For the purposes of clarity and completeness, some components have been deliberately excluded from this workshop manual and described in their own specific documentation. Changes may be made at short notice and at any time, and are communicated via service information documents. The documentation comprises operating instructions, additional workshop manuals, special documentation and circuit diagrams

Foreword
Product overview for the RX20 Facelift 2014

A “lithium-ion technology” variant of the RX20 family has been available since August 2016. The truck must be ordered with the “Li-Ion ready” setup pre-installed to ensure that the lithium- ion battery can communicate with the truck. The truck is converted from lead-acid battery operation to lithium-ion battery operation via parameterisation. The “Li-Ion ready” setup can be retrofitted in trucks that do not have it pre-installed.

TABLE OF CONTENTS:

STILL STED Forklift Electric trucks Facelift 2014  including lithium-ion technology RX20-14 RX20-15 RX20-16 RX20-18 RX20-20 Workshop Manual – PDF DOWNLOAD

00 Product information
Foreword 00
Product overview for the RX20 Facelift 2014 00
Safety information 00
Parking the truck so it is secured for service work 00
Working on the electrical system 00
Jacking up the rear of the truck 00
Jacking up the front of the truck 00
Securing the fork carriage 00
Restrictions and obligations 00
Speed limitation with lithium-ion battery 00
Penalties 00
Speed limitation with a Tensor battery 00
Speed limitation with high lift masts. 00
Speed limitation for legal use on public roads 00
01 Service
Maintenance 01
Maintenance instructions 01
Maintenance – 1000 hours/annually 01
Maintenance – 3000 hours/every two years 01
Operating materials 01
Measuring instruments and testing equipment 01
Harnesses and hoists, 1.0 t to 3.5 t 01
Standardised tightening torques for standard-pitch threads and fine-pitch threads 01
Standardised tightening torques for hose fittings 01
02 Diagnostics
Introduction to DiaMon 02
STEDS-Navigator 02
Diagnostics service box 02
Diagnostic set-up 02
Starting DiaMon 02
VIII 56328012001 EN – 01/2020
Table of contents
Working with DiaMon 02
Reading out access codes 02
Error list via DiaMon 02
Working using the ABE 02
Read error list 02
Clearing error lists 02
11 Electric motor
Traction motor 11
General technical data 11
Electrical connections 11
Traction drive 11
Sensors 11
Pin sensor 11
Temperature sensor PT1000 11
Temperature sensor KTY84 11
22 Mechanical drive axle
AE18-09 drive axle 22
General technical data 22
AE18-09 drive axle 22
Removing the drive wheel unit 22
Changing the shaft seal on the drive wheel unit 22
Refitting the drive wheel unit 22
Traction motor – Removing the rotor 22
Traction motor – Replacing the bearing and shaft seal 22
Traction motor – Installing the rotor 22
AE18-09 service brake 22
Dismantling the brake 22
Assembling the brake 22
Checking the oil level, changing the oil 22
30 Chassis, bodywork and fittings
Chassis 30
Battery door 30
Table of contents
Counterweight 30
Counterweight 30
Overhead guard 30
Overhead guard 30
42 Steering system
Hydraulic steering 42
General technical data 42
Steering system 42
Steering – error detection 42
Steering unit 42
Priority valve 42
Steering wheel with steering column 42
Steering column 42
Steering angle sensor 3B01 42
Steering angle-dependent handling performance – CSC 42
CSC – functional test 42
Steering turntable 42
General technical dataFifth wheel 42
Fifth wheel 42
Curve switch 42
Removing/installing the fifth wheel 42
Swing axle 42
General technical data, swing axle 42
Swing axle 42
Swing axle curve switch 42
Removing/installing the swing axle 42
Wheel hub 42
Steering angle 42
Tie rod 42
Axle stub 42
50 Operating devices
Accelerator pedal 50
Accelerator pedal, generation 2 50
Accelerator – single-pedal 50
Accelerator – dual pedal, generation 2 50
Table of contents
Brake actuation 50
Brake actuation 50
Brake sensor 50
Parking brake switch 1 S3 50
Changing the AE18-09 brake cable 50
Handbrake cable changer 50
Actuating force of the handbrake 50
Electric parking brake 50
Electric parking brake 50
Function 50
Cause and effect 50
Design and system description 50
Maintenance instructions 50
Checking the brake 50
Calibration and functional test 50
Changing the parking brake cable 50
Limit position switch 50
Drive unit Installation and removal 50
Central lubrication device Installation and removal 50
Hydraulic actuation 50
Hand lever 50
Joystick 4Plus 50
Axle assignment – Joystick 4Plus 50
Generation 2 mini-lever 50
Axle assignment – the mini-lever 50
Tip switch 50
Axle assignment – fingertip switch 50
Switches 50
Dead man switch 7S13 50
56 Display elements
Operating console 56
Turn indicator module for the drive direction, generation 2 56
Display 56
Display and operating unit, generation 2 (ABE 2) 56
ABE 2 Installation and removal 56
Table of contents
60 Electrics/electronics
General 60
General technical data – 48 V 60
Overview of the controllers 60
Electrical system 60
Electrical components 60
Switch-on process for the electrical system 60
Software compatibility 60
PAN process 60
Parameter management 60
Error ring buffer 60
Temperature monitoring for the traction motor – 48 V 60
Temperature monitoring for the traction motor converter 60
Pump motor temperature monitoring 60
Temperature monitoring for the pump motor converter 60
Available driving behaviour 60
Revolution-controlled vs. torque-regulated 60
Sprint mode 60
Blue-Q = IQ 60
Starting current boost 60
Stopping on a slope 60
Electrical checks 60
Intermediate circuit 60
Insulation testing for electric trucks 60
Insulation testing on the drive battery 60
Insulation testing the lithium-ion battery 60
Component insulation testing 60
Wiring 60
CAN bus system 60
CAN bus connections 60
Power cables 60
Maintenance guidelines for power cables 60
Repair – Contact elements 60
Electrical system 60
Fuse box (PDU) 60
Fuses 60
Contactor 60
Table of contents
Sensor system 60
Vertical lift mast position 60
Tilt angle sensor 7B46 60
Installation of the vertical lift mast position 60
Load measurement 60
Load measurement pressure sensor 60
Additional electrical installation 60
7 A21 converter PCB 60
Option Board 60
CAN-Power-Port (CPP) 60
CPP 1/CPP 3 60
CPP2B 60
CPP battery carrier (CPP5) 60
Relay-Power-Port 60
64 Electronic controls
Truck control unit 64
Main Control Unit (MCU 2) 64
Main Control Unit (MCU) Removal and installation 64
Supply Unit (SU 2) 64
Supply Unit (SU) Removal and installation 64
Converter 64
Inverters 64
SAC 1.1 converter – 48 V 64
Removing and installing the converter 64
69 Batteries and accessories
Battery male connector 69
Approved battery male connectors in the RX20 Facelift 2014 69
Battery plug 69
Battery male connector for lithium-ion batteries 69
Maintenance work for appliance plugs 69
Repair – Battery male connector contacts 69
Working with reducer sleeves 69
Table of contents
Lead-acid battery 69
General technical data 69
Battery 69
2014 discharge indicator 69
Lithium-ion technology 69
Working on lithium-ion batteries 69
General technical data 69
Battery management system (BMS) 69
Diagnostics 69
Battery display 69
Battery discharge indicator for a lithium-ion battery 69
Battery charge 69
Battery discharge 69
Course of action for a deeply discharged battery 69
Zero voltage check on the battery male connector 69
Removing/installing the battery cable 69
Converting from a lead-acid battery to a lithium-ion battery 69
70 Hydraulics
General 70
General technical data 70
Depressurising the hydraulics 70
Operating speeds for lifting 70
Operating speeds for lowering 70
Tilting operating speeds 70
Safety check 70
Forward tilt safety test 70
Lowering safety test 70
Safety checks of hose assembly 70
Basic hydraulics 70
Basic hydraulics 70
Steering hydraulics 70
Working hydraulics 70
Hydraulic tank 70
Hydraulic oil 70
Return line filter 70
Breather filter 70
Intake filter 70
Table of contents
High-pressure filter 70
Conical nipple fittings (CNF) 70
Bolted joint 70
71 Working hydraulics
Pump-motor unit 71
General technical data 71
Pump unit 71
Temperature sensor pump motor 71
Pump motor removal 71
Pump motor installation 71
Hydraulic pump 71
Hydraulic pump Removal and installation 71
Tilt cylinder 71
Mast tilt 71
Tilt cylinder Removal and installation 71
Changing the set of seals (1500 – 2000 kg) 71
Auxiliary hydraulics 71
Attachments 71
Second operating function for attachments 71
Clamp locking mechanism with servo hydraulics 71
Clamp locking mechanism for hand levers 71
Accumulator 71
Accumulator 71
Checking the accumulator 71
76 Valves
Hand lever 76
General technical data 76
Hand lever valve block 76
Emergency lowering 76
Hydraulic transmitter 76
Dismantling and installing valve block 76
Table of contents
Directional control valve with blocking function (Buchholz) 76
Directional control valve with check valve 2Y 46 76
Discharge pressure governor (lowering brake) 76
Check valve for hydraulics blocking function 76
Servo hydraulics 76
General technical data 76
Servo hydraulics valve block 76
Manual lowering 76
Directional control valve block 76
Directional control valve – method of operation 76
80 Load lift system
Mast bearing 80
Mast bearings, 1.0 t – 2.0 t 80
81 Lift mast
Lift mast 81
General technical data 81
Hose safety valve of triplex mast 81
Support roller play (108/117/130) 81
Load chains – Checking and cleaning 81
Run-out barrier 81
Working on lift masts 81
Lift mast – removal 81
Lift mast – installation 81
Telescopic lift mast 81
Telescopic lift mast (108/117/130) 81
Adjusting the load chains Telescopic lift mast (108/117/130) 81
NiHo lift mast 81
NiHo lift mast (108/117/130) 81
Adjusting the load chains Ni Ho lift mast ( 108/117 /130) 81
Triplex lift mast 81
Triple lift mast (108/117/130) 81
Removing the support rollers in the lift mast 81
Assembling the lift mast after replacing the support rollers 81
Outer load chains and chain rollers 81
Middle load chain and chain roller 81
XVI 56328012001 EN – 01/2020
Adjusting the outer load chains Triple lift mast ( 108/117 /130)
Adjusting the middle load chain Triple lift mast ( 108/117 /130)
Lift cylinder
Lift jack
Working on lift cylinders
Outer cylinder
Disassembling/assembling the outer cylinder
Centre cylinder
Disassembling/assembling the middle cylinder
End position damping, type B (bottom)
End position damping, type A (top)
84 Load support
Fork carriage
Fork carriage
Annex
X Circuit diagrams
Hydraulics
Hand lever from calendar week 39/2009
Servo hydraulic

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.M